Preassembled wall frame



Nov. 19, 1963 J. G. COSTELLO PREASSEMBLED WALL FRAME 2 Sheets-Sheet 1 Filed July 16. 1959 H. J m n m 0 m Nu A m 0 m f I KL: d l nk w QN F. d a 6 H W \wfi L M? j\% 4 & B aw 9 mw K m j l mu .mJL

I W NW Nov. 19, 1963 .1. G. COSTELLO 3,111,202

PREASSEMBLED WALL FRAME Filed July 16, 1959 2 SheetsPSheet 2 P, p; 22 I. i

! 7 I! w W 1 1- 2'6 7/ 76 INVENTOR Jof/n 6 (mid/0 ATTORNEY 3,111,202 Patented Nov. 19, 1963 3,111,202 PREASSEMBLED WALL FRAME John G. Costello, Tonawanda, N.Y., assignor to National Gypsum Company, Buffalo, N.Y., a corporation of Delaware Filed July 16, 1959, Ser. No. 827,594 2 Claims. (Cl. 189-34) This invention relates to improvements in stud and runner wall frames and more particularly to a preassembled foldable and unfoldable wall frame.

In constructing the frames of buildings, partitions, walls, etc. it is common practice to employ metallic studs secured at the top and bottom to metal ceiling and floor channel runners respectively, by separate metallic shoes. However, this type of construction has an inherent disadvantage. The studs, shoes and runners of such conventional construction must be bundled and shipped to the job site as separate elements, thereby requiring on the job assembly and erection, all of which unduly increases the labor costs.

Accordingly, it is a primary object of this invention to overcome this and other disadvantages of the prior art by providing an improved stud and runner wall frame which eliminates the necessity for separate metallic shoes entirely, which frame can be readily preassembled at the site of fabrication, folded for shipment, and quickly unfolded and erected at the construction site, which frame, while especially adapted for use in forming non-load bearing walls, can also be adapted for use in forming load bearing walls, and which frame automatically accommodates itself to variations in floor to ceiling height when used as a non-load bearing wall, all of which substantially reduces assembly, shipping and construction costs, especially on-the-job labor costs.

Still other objects and advantages of the invention will become apparent upon consideration of the following detailed description and the accompanying drawings wherein:

FIG. 1 is a side elevational view illustrating a wall frame constituting a preferred embodiment of the invention in the preassembled, partially folded condition;

FIG. 2 is a side elevational view of the wall frame of FIG. 1 in erected or unfolded condition;

FIG. 3 is an end elevational sectional view partially broken away and taken on line 3--3 of FIG. 2;

FIG. 4 is an enlarged partial elevational view of the connection between the lower end of a stud and a floor channel runner incorporated in the wall frame of FIGS. 1-3, and illustrates one embodiment of the lugs on the stud and the slots in the runner forming the connection therebetween;

FIG. 5 is a partial perspective view of the lower end of the stud and the lugs illustrated in FIG. 4;

FIG. 6 is a partial elevational view similar to FIG. 4 but illustrating a modification of the lugs on the stud and the slots in the runner;

FIG. 7 is a partial elevational view of the stud and lugs illustrated in FIG. 6;

FIG. 8 is a partial elevational view similar to FIGS. 4 and 6, but illustrating a further modification of the lugs on the stud, and

FIG. 9 is a partial perspective view of the stud and lugs illustrated in FIG. 8.

Referring to FIGS. l-5 of the drawing, and particularly FIGS. 13, the wall frame constituting a preferred embodiment of the invention and generally indicated at 10 is especially adapted for use in forming non-load bearing walls, and is preferably composed of identical floor and ceiling channel runners or tracks generally indicated at 11 and 12 respectively, these runners preferably being about 10 feet in length and connected by a plurality of transverse studs generally indicated at 13. Each channel runner, as clearly shown in FIG. 3, is composed of a web 14 preferably provided with longitudinally spaced central openings 15 for the reception of plumbing and electrical connections, etc., and each web terminates in outstanding flanges 16, each flange being provided with a plurality of longitudinally spaced and elongated transverse slots 17 arranged in transverse alinement, for a purpose to be described below.

Each stud 13, as best seen in FIGS. 3 and 5, is prefcrably composed of a pair of L-shaped angles 18 preferably slightly less than ceiling height and connected by a sinuous rod 20 welded adjacent the inner corners of the L-shaped channels. Adjacent each end, the stud 13 is provided with a rod 21 welded to the opposed legs of the L-shaped angles 18 and extending transversely beyond the parallel legs thereof to form outstanding transverse lugs 22.

As illustrated in FIGS. 3 and 4 particularly, the angles 18 of each stud 13 are spaced to fit snugly within the flanges 16 of runners 11, 12 and the lugs 22 on the ends of rods 21 are adapted to extend through the slots 17 in flanges 16. Inasmuch as the slots 17 are elongated, the studs 13 and runners 11, 12 can reciprocate as well as rotate relative to each other, and the ends of the angles 18 of studs 13 are adapted to make firm abuting engagement with the webs 14 of the runners.

In assembling the inventive wall frame 10, each stud 13 is rotated about its longitudinal axis to fit diagonally into the runner 11 or 12 and the lug 22 on one side of the stud is engaged in slot 17 in the flange on one side of the runner, after which the stud is rotated to snap the lug 22 on the opposite side thereof into frictional engagement with the corresponding transversely alined slot 17 in the flange on the opposite side of the runner. This action is made possible by the resiliency of the flanges 16 which can spread slightly to facilitate the assembly operation. After each of the studs 13 is inserted in the corresponding pair of slots 17 in opposed flanges of the channel runners 11, 12 the studs being preferably spaced the usual distance of 16 inches on centers, the wall frame 10 can then be folded, as partially shown in FIG. 1, because of the relatively repicrocal and rotatable connections between lugs 22 and slots 17, which permit the studs to be actually folded between the runners so that the studs become superposed one upon the other and partially overlap each other, while the runners remain substantially parallel but have their adjacent end portions overlapping each other. On this feature, it is to be noted that the fit between lugs 22 and slots 17 is snug enough to prevent any undesirable play laterally of the slots along the runners while at the same time permitting the aforesaid relative reciprocation and rotation. It is also to be understood that FIG. 1 is somewhat unrealistic to the extent that there will be actual contact between the folded studs and the vertical height or distance between the runners will be considerably less than shown when the wall frame is completely folded. However, FIG. 1 does illustrate the individual studs with much greater clarity than would be possible, were the frame shown as completely folded, and thus the partially folded condition of the wall frame has been selected for the sole purpose of clarity of illustration.

Referring now to the modification illustrated in FIGS. 6 and 7, lugs 22 of the rods 21 on studs 13 terminate at their free ends in enlarged heads or buttons 23, and the slots 17 in the flanges 16 of channels 11, 12 terminate in enlarged holes 24 adjacent the free ends of the flanges. In this type of construction, assembly of the studs 13 and runners 11, 12 is facilitated by the free passing of the enlarged heads 23 through the holes 24, as the studs are rotated into position, and accidental disassembly of the studs and runners is positively prevented by the heads 23 which positively engage the slot defining portions of the outside of the flanges 16 except when the heads and holes are alined. This construction has the further advantage of positively preventing any desirable play between the studs and runners laterally of the runners as the heads 23 are designed to fit snugly against the outsides of the flanges 16.

Another modification of the lugs on the studs is shown in FIGS. 8 and 9. In this construction, the rods 21 and heads 23 are eliminated entirely, and the lugs 25 are formed by striking out a portion of the parallel legs of the L-shaped angles 18. This lug construction is more economical than those shown in FIGS. 1-7, but does not have the inherent strength thereof, and is therefore limited to light duty installations.

The material used for the various elements of wall frame 10 is preferably metal. For example, the channel runners 11, 12 may be fabricated of suitable gauge sheet steel for light weight, strength and flexibility to conform with the variations in floor and ceiling surfaces. The angles 18 of the studs 13 are preferably formed of suitable gauge steel for combining both light weight, strength and rigidity. In addition, the rods 20, 21 are preferably formed from suitable lengths and diameter of steel bars providing both strength and flexibility, especially for blending of the sinuous rods 20. At the same time, it will be apparent that other suitable materials may be used for each of the aforesaid elements of the wall frame 10. Furthermore, while the above described and illustrated frame constituting a preferred embodiment of invention is primarily adapted for use in non-load bearing installations, it can readily be adapted for use in forming a load bearing wall also. For example, the angles 18, runners 11, 12 and rods 20, 21 could be made sufficiently stronger and more rigid for this purpose, the abutting engagement permitted between the studs 13 and runners 11, 12 by the slots 17 providing a sufficiently firrn and stable support. Alternatively, the studs 13 could be made of solid metal instead of hollow, or even be replaced by conventional wood two by fours which could be easily provided with the desired lug forming rods in any suitable manner.

It will now be seen how the invention accomplishes its various objects and provides numerous advantages over the prior art construction. The entire frame 10 is made of strong yet light weight and easily fabricated materials, and the flexible runners will readily conform to variations in floor and ceiling surfaces especially when the frame is used in non-load bearing installations. The unique lug and slot connections between the studs and runners completely eliminate the need for separate stud and runners fastening shoes, facilitate the assembly of the frame, its being readily folded, collapsed or knocked down and bundled in preassembled condition for economical shipment and quickly unfolded, extended or expanded and erected at the building site. These unique connections permit the ends of the studs 13 to make firm and stable abutting engagement with the runners 11, 12 which is especially useful when the frame is used in load bearing installations and they permit the frame to automatically accommodate itself to variations in floor to ceiling height, when interposed as a non-load bearing partition between the already existing floors and ceilings of buildings. Furthermore, the inventive wall frame can be readily used for both exterior and interior walls, it being but a simple matter to provide the required door and/or window openings in the frame while it is merely laying on the floor after being unfolded and before erection thereof.

When the frame is adapted for use in forming nonload bearing walls for example, it is merely unfolded and erected, after which the floor and ceiling runners are secured to the floor and ceilings of the building respectively, thereby providing a wall which is quickly and easily erected and secured in place, and which automatically accommodates itself to variations in floor to ceiling height. When the frame is adapted for use in forming load bearing walls on the other hand, as during the construction of various types of buildings, it is merely unfolded, and after the required door and window openings, if any, are made therein, the ceiling runner is nailed to one or more wood plates in the usual manner, and these plates, which are located so as to overlap individual frames, lock the frames together after they are erected and anchored to the floor, thereby providing rigid load bearing walls which are also quickly and easily erected and secured in place.

While only certain embodiments of the invention have been shown and described herein, it is to be understood that various changes and modifications may be made therein by those skilled in the art without departing from the spirit of the invention, the scope of which is to be determined by the appended claims.

What is claimed is:

1. A preassembled foldable and unfoldable Wall frafme comprising a plurality of runners each having a web and an outstanding flange provided with a plurality of longitudinally spaced, elongated transverse openings, and a plurality of studs each having both ends facing said webs and provided adjacent both ends with lateral lug means extending into said openings in said flanges and connecting said studs and runners, said lug means being reciprocable along and rotatable in said openings, thereby permitting relative reciprocation and rotation between said studs and runners.

2. A preassembled foldable and unfoldable wall frame comprising a pair of runners each having a web terminating in outstanding flanges each provided with a plurality of longitudinally spaced, elongated transverse slots each terminating in an enlarged hole adjacent the free edge of the corresponding flange, and a plurality of studs each having both ends arranged in said runners and facing said webs, each stud being provided adjacent both ends with outstanding transverse lugs extending through said slots in said flanges and connecting said studs and runners, said lugs being reciprocable along and rotatable in said slots, thereby permitting relative repicrocation and rotation between said studs and runners as well as firm abutting engagement between said ends of said studs and said webs of said runners, each lug terminating at its free end in an enlarged head passable through the corresponding hole in the corresponding flange to facilitate assembly of said studs and runners and engagement with the slot defining portion of said corresponding flange to prevent disassembly of said studs and runners except when said head is alined with said corresponding hole.

References Cited in the file of this patent UNITED STATES PATENTS 734,781 Walker et al. July 28, 1903 1,096,221 Caldwell May 12, 1914 2,081,368 Pretot May 25, 1937 2,250,798 Gibson et a1. July 29, 1941 2,271,472 Balduf Jan. 27, 1942 2,301,306 McDonol Nov. 10, 1942 FOREIGN PATENTS 470,255 Great Britain Aug. 9, 1937 

1. A PREASSEMBLED FOLDABLE AND UNFOLDABLE WALL FRAME COMPRISING A PLURALITY OF RUNNERS EACH HAVING A WEB AND AN OUTSTANDING FLANGE PROVIDED WITH A PLURALITY OF LONGITUDINALLY SPACED, ELONGATED TRANSVERSE OPENINGS, AND A PLURALITY OF STUDS EACH HAVING BOTH ENDS FACING SAID WEBS AND PROVIDED ADJACENT BOTH ENDS WITH LATERAL LUG MEANS EXTENDING INTO SAID OPENINGS IN SAID FLANGES AND CONNECTING SAID STUDS AND RUNNERS, SAID LUG MEANS BEING RECIPROCABLE ALONG AND ROTATABLE IN SAID OPENINGS, THEREBY PERMITTING RELATIVE RECIPROCATION AND ROTATION BETWEEN SAID STUDS AND RUNNERS. 